JPH0560769B2 - - Google Patents

Description

[Detailed description of the invention] (b) Industrial application fields The present invention relates to a method for manufacturing artificial marble.

(b) Conventional technology In the past, thermosetting synthetic resin materials such as unsaturated polyester mixtures were poured into molds with an opening on the top, waited for curing, and then molded into synthetic resin products such as washstand counters and tables. There is a method for manufacturing tops, etc. Furthermore, as seen in Japanese Patent Publication No. 59-1568, in order to make a pattern appear on the thermosetting synthetic resin material that is the base material during the casting process, There is a method of manufacturing artificial marble that imitates natural marble patterns on the surface of the product by mixing colored synthetic resin materials.

(c) Problems to be solved by the invention However, the appearance of patterns in this method is
It is strongly influenced by chance, and this chance causes the moderately irregular distribution of the stripes, the thickness of the stripes, the bleeding of the pattern, the contrast, etc., resulting in the texture of natural marble. However, when actually manufactured using this method, the stripes may be distributed extremely unevenly, the stripes may be too thick or too thin, the pattern may be blurred, or the contrast may be too strong. In most cases, the texture of natural marble does not appear and the product feels unnatural, resulting in an extremely low yield of good products.

As mentioned above, products are strongly influenced by chance, so sometimes products with a natural texture are produced with a good balance of stripe distribution, stripe thickness, pattern bleeding, contrast, etc. A method for controlling the above-mentioned irregularities has not been established, and yield improvement has not yet been achieved.

(d) Means for Solving the Problems In this invention, a thermosetting synthetic resin material serving as a base material and a colored synthetic resin material for forming a pattern are housed in a hopper, and the hopper is placed in the surface of the upper opening. By discharging each synthetic resin material in the form of a film from the slit-shaped discharge port at the lower end of the hopper while advancing along the mold, a band-shaped patterned synthetic resin material is supplied into the table mold and thermally cured. , in a method for manufacturing plate-shaped artificial marble, when storing a thermosetting synthetic resin material and a colored synthetic resin material for pattern appearance in a hopper, the thermosetting synthetic resin material serving as the base material is , provides a method for manufacturing artificial marble, characterized in that a mixed material in which a colored synthetic resin material for pattern appearance is suspended is caused to flow into a hopper by reciprocating in the longitudinal direction of a discharge port by a necessary means. This is what I am trying to do.

(E) Effect The above-mentioned marble pattern appearance phenomenon is strongly related to the flow and diffusion of the viscous synthetic resin material, and although such rheological phenomena are extremely difficult to analyze, up to now The trial revealed the following, albeit qualitatively.

The discharge opening of the hopper for casting is formed into a substantially slit shape, and when the hopper is moved and the above synthetic resin material flows down into the mold in a substantially film shape, it contacts the mold and forms the product surface. The majority of the composition of the synthetic resin comes from near the inner surface of the front wall in front of the hopper in the direction of movement.

The synthetic resin material for the base material, which makes up the majority of the material, and the colored synthetic resin material, which has a slight difference in amount, are as follows.
In the case of pouring from a hopper, only a slight amount of mixing occurs, and the composition of the colored synthetic resin material gradually spreads to the surrounding area from the area where the composition is high.

When the synthetic resin material flows into the hopper, if the colored synthetic resin material is suspended on the surface of the synthetic resin material in the raw material container, when the raw material container is tilted and flows into the hopper, the approximately line The plastic material is stretched into a shape, and simultaneously flows down onto the upper surface of the synthetic resin material for the base material that is flowing down.

The width of the colored synthetic resin material stretched into the above-mentioned approximately linear shape is thick at first and gradually becomes thinner, but it does not necessarily become thinner uniformly, but gradually pulsates irregularly as it becomes thicker and thinner. I'm getting older.

When the mixed material flows into the hopper, if the colored synthetic resin material comes into contact with the inner surface of the front wall of the hopper that is not covered with the mixed resin material or has a thin layer of the same material, the same colored synthetic resin material will It adheres to the inner surface of the wall and hardly spreads as it is.

The colored synthetic resin material attached to the inner surface of the front wall is
It does not flow out all at once, but gradually flows out due to the outflow of nearby synthetic resin materials.

The present invention was made based on the above knowledge, and first, a colored synthetic resin material for pattern appearance is gently injected onto the surface of the synthetic resin material for the base material before it flows into the hopper. When the mixed material is floated on the same surface and then flows into the hopper, the colored synthetic resin material on the upper surface of the flowing mixed material flows down into the hopper while being stretched in a substantially linear shape.

During the above-mentioned inflow, by performing the inflow while reciprocating the hopper or raw material container in the longitudinal direction of the discharge port, the colored synthetic resin material stretched in the above-mentioned approximately linear shape is transferred to the hopper. It can be accommodated in the hopper in a reciprocating meandering state over its full width.

Next, by flowing the synthetic resin material in the form of a film through the slit-shaped discharge port of the hopper into the surface mold, the colored synthetic resin material stored in the hopper in a meandering state is removed from the synthetic resin material in the base material. As the liquid flows down, it flows down into the surface mold and is injected into the lowest part of the surface mold, creating a striped pattern on the surface of the product whose length is in the direction of flow, that is, the direction in which the hopper moves.

As mentioned above, the reason why the colored synthetic resin material meandering in the direction transverse to the flow direction forms a striped pattern in the direction perpendicular to this is due to the effect of turbulence in the flow of the mixed material in the hopper, considering the Ray-Nozzle number. Although it is difficult to imagine, since such a phenomenon has actually occurred in trials to date, it is reasonable to think as follows.

When the mixed material flows in the hopper, there is a high probability that the linear colored synthetic resin material meandering in the lateral direction will be separated due to the shearing action at the interface where the flow velocity changes discontinuously.

Since the colored synthetic resin material is located on the surface of the mixed material flowing into the hopper, the colored synthetic resin material is located at the interface of the thixotropic mass, and the flow of this mass creates a linear shape. There is a high probability that the colored synthetic resin material will rotate or break.

The colored synthetic resin rotated or divided as described above flows down in the form of a film from the middle part of the hopper, which has a wide horizontal cross-sectional area, through the slit-shaped discharge port, which has a narrow cross-sectional area, and is stretched in the direction of flow. This results in a striped pattern whose length is in the downstream direction, that is, in the direction in which the hopper moves.

In addition, the pattern that appears when colored synthetic resin material adheres to the inner surface of the front wall of the hopper is that the colored synthetic resin material that was attached to the inner surface of the front wall of the hopper is replaced by the synthetic resin for the base material flowing down. Since it is caused by being dragged by the material, it naturally becomes a striped pattern whose length is in the direction of movement of the hopper.

In addition, the above-mentioned colored synthetic resin material, both when it is attached to the inner surface of the front wall of the hopper and when it is not, is affected by the flow within the hopper, the flow down from the discharge port, and the flow within the table mold. It does not spread greatly, and it gradually becomes thinner towards both sides, centering on the area where there is a large amount of colored synthetic resin material, and moreover, the hopper contains synthetic resin material for the base material and colored synthetic material for pattern appearance. When the resin material flows in, it reciprocates in the longitudinal direction of the discharge port, so the mixed position of the colored synthetic resin material is irregularly distributed over the entire width of the hopper in the advancing direction, and the amount of adhesion is also uneven. However, the degree of irregularity depends on the probability, so the larger the number of meanderings mentioned above, the smaller it becomes. Therefore, the distribution of the stripes, the thickness of the stripes, and the contrast of the pattern By setting the optimum meandering number of times through several trials, it is possible to create a striped pattern on the surface of the product that closely resembles the pattern of Italian natural marble. can.

Then, after waiting for both synthetic resin materials injected into the surface mold to harden, they are removed from the mold to create the finished product, artificial marble.

(f) Effects According to the present invention, the distribution of stripes appearing on the surface of the product, the thickness of the stripes, the contrast and the extent of bleeding, etc. can be controlled by the action based on the above method. It is possible to produce artificial marble with a natural texture similar to Italian marble.

(G) Examples The method for producing artificial marble according to the present invention will be explained in detail based on drawings of an apparatus for carrying out the method. A in FIGS. 1 to 3 shows the apparatus for producing artificial marble. , the device A consists of a top-opening table mold 2 placed on a base 1 with its longitudinal axis extending in the left-right direction, and left and right rails 3 arranged in the left-right direction provided at the upper rear side of the table mold 2.
, a hopper support frame 5 which is suspended from the same rail 3 so as to be movable left and right and is provided with front and rear rails 4 in the front and rear directions, a hopper 6 which is supported by the front and rear rails 4 so as to be movable back and forth, and a hopper 6 that is combined with the hopper 6. A bottomed, substantially cylindrical raw material container 8 into which the resin material 7 is introduced, a heavy lifting machine such as a lift or a chain block (not shown) for lifting the raw material container 8, and a back mold (not shown). ).

Table type 2 is a roughly rectangular shape with its length running in the left and right direction.
A protrusion 2a for forming an opening into which a washbasin (not shown) is inserted is provided approximately at the center.

The hopper support frame 5 includes a vertical frame 10 extending vertically downward from the left and right rails 3, and a lower end of the vertical frame 10.
The front and rear rails 4, which are approximately twice as long as the front and back length of the hopper 6 described below and have rollers 4a on the upper surface, are arranged horizontally in the front direction. It is configured such that it can be raised by rotating the handle 5b.

Therefore, the hopper 6 is supported in a cantilever manner above the table mold 2 at the diagonally front lower part of the left and right rails 3, and can move back and forth across the full front and rear width of the hopper 6. It is possible to move left and right over the entire length of the mold 2 and to adjust the height from the front mold 2.

The hopper 6, which is one of the features of the present invention, has a fourth
As shown in the figure, it has a substantially rectangular shape with its long side in the front-back direction when viewed from above, and the long side has approximately the same length as the front-to-back width of the table mold 2. The inner side surface 11 of the front wall on the side in the traveling direction of the first pass is formed into a substantially planar shape and is inclined to be high in the front and low in the rear. The side shape of the inner side surface 11 of the front wall is as follows.
It is formed into a substantially rectangular shape.

Further, a longitudinally slit-shaped discharge port 12 is provided at the lower end of the hopper 6 and has a length that opens downward and is approximately the same as the longitudinal width of the table mold 2.
A shutter 13 is provided below the discharge port 2 to open and close the discharge port from below.

In particular, the opening/closing operation of the discharge port 12 is performed by sliding the shutter 13 in the left-right direction, so that the thickness of the film-like synthetic resin material flowing down from the discharge port 12 can be adjusted. .

The back mold (not shown) is substantially plate-shaped and has an outer shape that matches the opening on the top surface of the front mold 2.

The artificial marble manufacturing apparatus used in the present invention is configured as described above, and in manufacturing the artificial marble, first, a thermosetting synthetic resin material for base material B mixed with a hardening agent is added to the raw material container 8. is injected into the material B, and a colored synthetic resin material C for pattern appearance is gently flowed down onto the surface of the same material B and suspended on the surface to form a mixed material D.

The mixed material D thus prepared is lifted together with the raw material container 8 by a lift or chain block, and the raw material container 8 is tilted to flow into the hopper 6 with the discharge port 12 closed. As shown, the water flows from the rear of the hopper 6 toward the front.

By doing this, a part of the colored synthetic resin material C stretched linearly on the upper surface of the mixed material D flowing down hits the inner surface 11 of the front wall located in front of the hopper 6 in the direction of movement. Front wall inner surface 11
Attach to.

Then, by reciprocating the hopper 6 back and forth while flowing the mixed material D as described above, the hopper 6 removes the material that has adhered to the inner surface 11 of the front wall of the colored synthetic resin material C and the material that has not. It will meander back and forth across the entire front and back width of the road.

The hopper 6 filled with both mixed materials D in this manner is positioned above the right end of the table mold 2, the discharge port 12 is opened, and the mixed materials D are allowed to flow down in a film form from the discharge port.

When the mixed material D flowing down in a film reaches the upper right end surface of the table mold 2, the hopper 6 is advanced to the left at a constant speed to make the minimum pass, and then the mixed material D is discharged from the discharge port 12. The mixed material D is poured over the entire surface of the table mold 2 by reciprocating left and right on the left and right rails 3 while flowing down in a film form.

During this casting, the degree of opening of the shutter 13 can be adjusted to optimally adjust the thickness of the mixed material D flowing down in a membrane flow.

The surface of the mixed material D injected into the surface mold in this way, which is in contact with the surface mold 2, that is, the surface of the product, is in the direction of movement of the hopper 6, that is, the surface of the product, as explained in the section of the above-mentioned action. Parallel stripes appear along the length.

The contrast of this striped pattern and the degree of bleeding are
This can also be controlled by the number of reciprocations of the raw material container when the mixed material D flows into the hopper 6, as explained in the section of the operation.

Then, the back mold 9 is placed on the top surface of the cast mixed material D to make the top surface flat, and the top surface of the mixed material D is covered to prevent the curing from being inhibited by air, and then heat curing is performed. and harden the same material,
It is demolded and made into artificial marble products.

The embodiment of the present invention is constructed as described above, and first, prior to casting, a colored synthetic resin material C for pattern appearance is suspended on the surface of the mixed material D flowing into the hopper 6. By flowing in, the colored synthetic resin material C on the upper surface of the mixed material D flowing down flows into the hopper 6 while being stretched in a substantially linear shape.

Also, at this time, since the hopper 6 is reciprocated along the length of the discharge port 12 while flowing in, the colored synthetic resin material C stretched in the above-mentioned approximately linear shape is transferred to the hopper as shown in FIG. It is accommodated in the hopper 6 in a reciprocating meandering state over the full width of the slit-shaped discharge port 12 of the hopper 6.

The width of the colored synthetic resin material C stretched into a substantially linear shape is thick at first and gradually becomes thinner, but it does not necessarily become thinner uniformly.
It becomes thicker and thinner, pulsating irregularly as it becomes thinner.

Therefore, the attachment points of the colored synthetic resin material C are irregularly distributed over the entire surface of the inner surface 11 of the front wall, and the amount of attachment also changes irregularly, and furthermore, the degree of this irregularity depends on probability. Therefore, as the number of meandering reciprocations increases, the size becomes smaller, so that the distribution of adhesion locations and the amount of adhesion can be controlled.

Next, the mixed material D is made to flow down into the table mold 2 from the slit-shaped discharge port 12 of the hopper 6 in the form of a film, and the first pass of the hopper 6 is directed forward, so that the hopper 6 is Front wall inner surface 1
The colored synthetic resin material C attached to the mold 1 is dragged down by the nearby mixed material D for the base material and flows down to one place, and is injected into the lowest part of the mold 2 to create a pattern on the surface of the product. put out

In this way, the exposed synthetic resin material C adhering to the inner surface 11 of the front wall of the hopper 6 is dragged by the flowing synthetic resin material B for the base material. The coloring synthetic resin material C has a striped pattern with its length extending in the direction of movement of the colored synthetic resin material C. Centering around the area where the composition is high, it gradually becomes thinner towards both sides of the area, and as mentioned above, the irregularity in the distribution and amount of the colored synthetic resin material C is controlled. Therefore, it is possible to control the distribution of the stripes, the thickness of the stripes, the contrast of the pattern, and the degree of bleeding, and by setting the optimal number of meandering round trips through several trials, the pattern closely resembles that of Italian natural marble. A striped pattern can be created on the surface of the product, and artificial marble with a natural texture can be manufactured with high probability.

[Brief explanation of the drawing]

FIG. 1 is an overall front view of a manufacturing apparatus for carrying out the method for manufacturing artificial marble according to the present invention. FIG. 2 is a side view of the same. FIG. 3 is a sectional view taken along the line of FIG. 2. FIG. 4 is a perspective view of the hopper. FIG. 5 is a perspective explanatory view showing the flow of the colored synthetic resin material into the hopper. FIG. 6 is an explanatory diagram showing how colored synthetic resin materials are accommodated in the hopper. B: Synthetic resin material for base material, C: Colored synthetic resin material for pattern appearance, D: Mixed material, 2: Surface type,
6: Hopper, 12: Discharge port.

Claims (1)

[Claims] 1 A thermosetting synthetic resin material B serving as a base material and a colored synthetic resin material C for pattern appearance are housed in the hopper 6, and while the hopper 6 is advanced along the top mold 2, Each synthetic resin material B, C is deposited in a film form from the slit-shaped discharge port 12 at the lower end of the hopper 6.
In the method of manufacturing a plate-shaped artificial marble by discharging a band-shaped patterned synthetic resin material into a table mold 2 and thermosetting it, a thermosetting synthetic resin material B is placed in a hopper 6. and the colored synthetic resin material C for pattern appearance are housed, a mixed material D in which the colored synthetic resin material C for pattern appearance is suspended in the thermosetting synthetic resin material B serving as the base material.
into the hopper 6 by the necessary means at the discharge port 12.
A method for manufacturing artificial marble, characterized by reciprocating the material in the longitudinal direction to allow it to flow in.